Generac GP6500 0056900 User manual

Brand: Generac

Model: GP6500 0056900

Category: Power generators

Type: User manual

www.generac.com or 1-888-436-3722

Owner's Manual

GP Series Portable Generator

MODELS: 005688-0, 005690-0,

005738-0

Introduction ............................................................. 1

Read this Manual Thoroughly ................................. 1

Safety Rules ........................................................... 2

Standards Index .............................................................3

General Information ................................................ 4

1.1 Unpacking ......................................................................4

1.1.1 Accessory Box ...................................................4

1.2 Assembly .......................................................................4

1.2.1 Assembling the Accessory Kit .............................4

Operation ................................................................ 4

2.1 Know the Generator .......................................................4

2.2 Hourmeter ......................................................................5

2.3 Cord Sets and Connection Plugs ....................................6

2.3.1 120 VAC, 20 Amp, Duplex Recepatcle.................6

2.3.2 120/240 VAC, 30 Amp Receptacle ......................6

2.4 How to Use the Generator ..............................................6

2.4.1 Grounding the Generator .....................................6

2.4.2 Connecting Electrical Loads ................................6

2.5 Don’t Overload the Generator ..........................................7

2.6 Wattage Reference Guide ...............................................7

2.7 Before Starting the Generator .........................................7

2.7.1 Adding Engine Oil ................................................7

2.7.2 Adding Gasoline ..................................................8

2.8 To Start the Engine .........................................................8

2.9 Stopping the Engine .......................................................9

2.10 Low Oil Level Shutdown System ....................................9

2.10.1 Sensing Low Oil Level .......................................9

Maintenance ........................................................... 9

3.1 Maintenance Schedule ...................................................9

3.2 Product Specifications ....................................................9

3.2.1 Generator Specifications .....................................9

3.2.2 Engine Specifications ..........................................9

3.3 General Recommendations ...........................................10

3.3.1 Generator Maintenance .....................................10

3.3.2 To Clean the Generator ......................................10

3.3.3 Engine Maintenance ..........................................10

3.3.4 Checking Oil Level ............................................10

3.3.5 Changing the Oil ...............................................10

3.3.6 Replacing the Spark Plug ..................................10

3.4 Service Air Filter ...........................................................11

3.5 Valve Clearance ............................................................11

3.6 General ........................................................................11

3.7 Long Term Storage .......................................................11

3.8 Other Storage Tips .......................................................11

Troubleshooting .................................................... 12

4.1 Troubleshooting Guide ..................................................12

Notes .................................................................... 13

Warranty ............................................................... 14

MANUAL DEL PROPIETARIO ............................. 15

MANUEL D'ENTRETIEN...................................... 31

Table of Contents

INTRODUCTION

Thank you for purchasing this model by Generac Power Systems,

Inc. This model is a compact, high performance, air-cooled,

engine driven generator designed to supply electrical power to

operate electrical loads where no utility power is available or in

place of utility due to a power outage.

READ THIS MANUAL THOROUGHLY

If any portion of this manual is not understood, contact the nearest

Authorized Dealer for starting, operating and servicing procedures.

The operator is responsible for proper and safe use of the

equipment. We strongly recommend that the operator read this

manual and thoroughly understand all instructions before using the

equipment. We also strongly recommend instructing other users to

properly start and operate the unit. This prepares them if they need

to operate the equipment in an emergency. Save these instructions

for future reference. If you loan this unit to someone, ALWAYS loan

these instructions to the individual as well.

The generator can operate safely, efficiently and reliably only if it

is properly located, operated and maintained. Before operating or

servicing the generator:

• Become familiar with and strictly adhere to all local, state and

national codes and regulations.

• Study all safety warnings in this manual and on the product

carefully.

• Become familiar with this manual and the unit before use.

The manufacturer cannot anticipate every possible circumstance

that might involve a hazard. The warnings in this manual, and on

tags and decals affixed to the unit are, therefore, not all inclusive.

If using a procedure, work method or operating technique that the

manufacturer does not specifically recommend, ensure that it is

safe for others. Also make sure the procedure, work method or

operating technique utilized does not render the generator unsafe.

THE INFORMATION CONTAINED HEREIN WAS BASED ON

MACHINES IN PRODUCTION AT THE TIME OF PUBLICATION.

GENERAC RESERVES THE RIGHT TO MODIFY THIS MANUAL AT

ANY TIME.

SAFETY RULES

Throughout this publication, and on tags and decals affixed to the

generator, DANGER, WARNING, CAUTION and NOTE blocks are

used to alert personnel to special instructions about a particular

operation that may be hazardous if performed incorrectly or

carelessly. Observe them carefully. Their definitions are as follows:

INDICATES A HAZARDOUS SITUATION OR

ACTION WHICH, IF NOT AVOIDED, WILL RESULT

IN DEATH OR SERIOUS INJURY.

Indicates a hazardous situation or action which,

if not avoided, could result in death or serious

injury.

Indicates a hazardous situation or action which,

if not avoided, could result in minor or moderate

injury.

NOTE:

Notes contain additional information important to a procedure

and will be found within the regular text body of this manual.

These safety warnings cannot eliminate the hazards that they

indicate. Common sense and strict compliance with the special

instructions while performing the action or service are essential to

preventing accidents.

Four commonly used safety symbols accompany the DANGER,

WARNING and CAUTION blocks. The type of information each

indicates is as follows:



This symbol points out important safety

information that, if not followed, could

endanger personal safety and/or property of

others.





This symbol points out potential explosion

hazard.



This symbol points out potential fire hazard.



This symbol points out potential electrical

shock hazard.

GENERAL HAZARDS

• Never operate in an enclosed area or indoors EVEN IF doors and

windows are open.

• For safety reasons, the manufacturer recommends that the

maintenance of this equipment is carried out by an Authorized

Dealer. Inspect the generator regularly, and contact the nearest

Authorized Dealer for parts needing repair or replacement.

• Operate generator only on level surfaces and where it will not be

exposed to excessive moisture, dirt, dust or corrosive vapors.

• Keep hands, feet, clothing, etc., away from drive belts, fans,

and other moving parts. Never remove any fan guard or shield

while the unit is operating.

• Certain parts of the generator get extremely hot during

operation. Keep clear of the generator until it has cooled to

avoid severe burns.

• Do NOT operate generator in the rain.

• Do not alter the construction of the generator or change

controls which might create an unsafe operating condition.

• Never start or stop the unit with electrical loads connected

to receptacles AND with connected devices turned ON. Start

the engine and let it stabilize before connecting electrical

loads. Disconnect all electrical loads before shutting down the

generator.

• Do not insert objects through unit’s cooling slots.

• When working on this equipment, remain alert at all times.

Never work on the equipment when physically or mentally

fatigued.

Introduction

• Never use the generator or any of its parts as a step. Stepping

on the unit can stress and break parts, and may result in

dangerous operating conditions from leaking exhaust gases,

fuel leakage, oil leakage, etc.

• On electric start models, disconnect the POSITIVE (+) battery

cable from the engine starter OR the NEGATIVE (-) battery

cable from the battery terminal, whichever is easier, before

transporting the generator.

EXHAUST & LOCATION HAZARDS

• NEVER use inside, or in partly enclosed areas such as

garages, EVEN IF doors and windows are open! ONLY use

outdoors and far from windows, doors and vents. Only use in

an area that will not accumulate deadly exhaust.

• The engine exhaust fumes contain carbon monoxide, which

you cannot see or smell. This poisonous gas, if breathed in

sufficient concentrations, can cause unconsciousness or even

death.

• Adequate, unobstructed flow of cooling and ventilating air

is critical to correct generator operation. Do not alter the

installation or permit even partial blockage of ventilation

provisions, as this can seriously affect safe operation of the

generator. The generator MUST be operated outdoors.

• This exhaust system must be properly maintained. Do nothing

that might render the exhaust system unsafe or in noncompliance

with any local codes and/or standards.

• Always use a battery operated carbon monoxide alarm indoors,

installed according to the manufacturers instructions.

• If you start to feel sick, dizzy, or weak after the generator has

been running, move to fresh air IMMEDIATELY. See a doctor, as

you could have carbon monoxide poisoning.

ELECTRICAL HAZARDS

• The generator produces dangerously high voltage when in

operation. Avoid contact with bare wires, terminals, connections,

etc., while the unit is running, even on equipment connected

to the generator. Ensure all appropriate covers, guards and

barriers are in place before operating the generator.

• Never handle any kind of electrical cord or device while

standing in water, while barefoot or while hands or feet are wet.

DANGEROUS ELECTRICAL SHOCK MAY RESULT.

• The National Electric Code (NEC) requires the frame and external

electrically conductive parts of the generator be properly

connected to an approved earth ground. Local electrical codes

may also require proper grounding of the generator. Consult

with a local electrician for grounding requirements in the area.

• Use a ground fault circuit interrupter in any damp or highly

conductive area (such as metal decking or steel work).

• Do not use worn, bare, frayed or otherwise damaged electrical

cord sets with the generator.

• Before performing any maintenance on the generator, disconnect

the engine starting battery (if equipped) to prevent accidental

start up. Disconnect the cable from the battery post indicated

by a NEGATIVE, NEG or (–) first. Reconnect that cable last.

• In case of accident caused by electric shock, immediately shut

down the source of electrical power. If this is not possible,

attempt to free the victim from the live conductor. AVOID

DIRECT CONTACT WITH THE VICTIM. Use a non-conducting

implement, such as a rope or board, to free the victim from the

live conductor. If the victim is unconscious, apply first aid and

get immediate medical help.

FIRE HAZARDS

• Gasoline is highly FLAMMABLE and its vapors are EXPLOSIVE.

Do not permit smoking, open flames, sparks or heat in the

vicinity while handling gasoline.

• Never add fuel while unit is running or hot. Allow engine to cool

completely before adding fuel.

• Never fill fuel tank indoors. Comply with all laws regulating

storage and handling of gasoline.

• Do not overfill the fuel tank. Always allow room for fuel

expansion. If tank is over-filled, fuel can overflow onto a hot

engine and cause FIRE or an EXPLOSION. Never store generator

with fuel in tank where gasoline vapors might reach an open

flame, spark or pilot light (as on a furnace, water heater or

clothes dryer). FIRE or EXPLOSION may result. Allow unit to

cool entirely before storage.

• Wipe up any fuel or oil spills immediately. Ensure that no

combustible materials are left on or near the generator. Keep the

area surrounding the generator clean and free from debris and

keep a clearance of five (5) feet on all side to allow for proper

ventilation of the generator.

Safety Rules

• Do not insert objects through unit’s cooling slots.

• Do not operate the generator if connected electrical devices

overheat, if electrical output is lost, if engine or generator sparks

or if flames or smoke are observed while unit is running.

• Keep a fire extinguisher near the generator at all times.

STANDARDS INDEX

In the absence of pertinent standards, codes, regulations and laws,

the published information listed below may be used as a guideline

for operation of this equipment. Always reference the latest revision

available for the standards listed.

1. NFPA No. 70, NFPA HANDBOOK OF NATIONAL ELECTRIC

CODE.

2. Article X, NATIONAL BUILDING CODE, available from the

American Insurance Association, 85 John Street, New York,

N.Y. 10038.

3. AGRICULTURAL WIRING HANDBOOK, available from the Food

and Energy Council, 909 University Avenue, Columbia, MO

65201.

4. ASAE EP-3634, INSTALLATION AND MAINTENANCE OF

FARM STANDBY ELECTRICAL SYSTEMS, available from the

American Society of Agricultural Engineers, 2950 Niles Road,

St. Joseph, MI 49085.

MODEL NO:

SERIAL NO:

Unit ID Location

CALIFORNIA PROPOSITION 65 WARNING

Engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects

and other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNING

This product contains or emits chemicals known to the

State of California to cause cancer, birth defects and

other reproductive harm.

Safety Rules

1.1 UNPACKING

• Remove all packaging material.

• Remove separate accessory box.

• Remove the generator from carton.

1.1.1 ACCESSORY BOX

Check all contents. If any parts are missing or damaged locate an

authorized dealer at 1-888-436-3722.

Contents Include:

• 1 – Owner’s Manual • 1 - Left Handle Assembly

• 1 - Quart Oil SAE 30 • 1 - Right Handle Assembly

• 2 - Never-Flat Wheels • 1 - Frame Foot

• 1 - Foot Support

• 1 - Hardware Bag (containing the following):

2 - Rubber Feet 2 - 5/16” Bolts

2 - 5/16” Flat Washers 4 - 5/16” Locking Flange

Nuts

4 - 5/16” Carriage Bolts 2 - 5/16” Locking Cap Nuts

2 - 1/2” Axle Bolts 2 - 1/2” Locking Flange

Nuts

2 - 1/2" Flat Washers

1.2 ASSEMBLY

The generator requires some assembly prior to using it. If

problems arise when assembling the generator, please call the

Generator Helpline at 1-888-436-3722.

1.2.1 ASSEMBLING THE ACCESSORY KIT

The wheels are designed into the unit to greatly improve the

portability of the generator.

NOTE:

The wheels are not intended for over-the-road use.

1. Refer to Figure 1 and install Wheels as follows:

• Slide the 1/2” Axle Bolt through the 1/2" Flat Washer, Wheel

and Wheel bracket on frame.

• Install 1/2” Locking Flange Nuts onto 1/2” Flange Bolt.

2. Refer to Figure 1 and install Frame Foot, Foot Support and

Rubber Feet as shown.

• Slide Rubber Bumper Stud through Foot Support and Frame

Foot, then install 5/16” Locking Flange Nuts.

• Slide Frame Foot onto 5/16” Bolts; Install 5/16” Locking

Flange Nuts.

3. Refer to Figure 2 and install Handles as shown.

• Remove top Curved Head Bolts and Cap Nuts (Cap Nuts will

be re-used).

• Slide Handle Assembly over Frame Tube, aligning 2 holes.

• Slide 5/16” Carriage Bolts through; Install 5/16” Cap Nuts.

Figure 1 – Wheel Assembly

FOOT SUPPORT

FOOT

Figure 2 – Install Handle Kit

2.1 KNOW THE GENERATOR

Read the Owner’s Manual and Safety Rules before operating this

generator.

Compare the generator to Figures 3 through 5 to become

familiarized with the locations of various controls and adjustments.

Save this manual for future reference.

1. 120 Volt AC, 20 Amp, Duplex Receptacle – Supplies electrical

power for the operation of 120 Volt AC, 20 Amp, single-phase,

60 Hz electrical lighting, appliance, tool and motor loads.

2. 120/240 Volt AC, 30 Amp Locking Receptacle – Supplies

electrical power for the operation of 120 and/or 240 Volt AC,

30 Amp, single-phase, 60 Hz, electrical lighting, appliance,

tool and motor loads.

3. Circuit Breakers (AC) – Each receptacle is provided with

a circuit breaker to protect the generator against electrical

overload.

General Information

Figure 3 - Control Panel

4. Hourmeter – Tracks hours of operation.

5. Air Filter – Filters intake air as it is drawn into the engine.

6. Choke Knob – Used when starting a cold engine.

7. Fuel Tank – Tank holds 6.6 U.S. gallons of fuel.

8. Grounding Lug – Ground the generator to an approved earth

ground here. See "Grounding the Generator" for details.

9. Run/Stop Switch – Controls the operation of the generator.

10. Muffler – Quiets the engine.

11. Handles – Pivot and retract for storage. Press the spring-

loaded button to move handles.

12. Gas Cap – Fuel fill location.

13. Fuel Gauge – Shows fuel level in tank.

14. Oil Fill – Add oil here.

15. Recoil Starter – Use to start engine manually.

16. Fuel Shut Off – Valve between fuel tank and carburetor.

17. Oil Drain – Use to drain engine oil.

Figure 4 - Generator Controls

Figure 5 - Generator Controls

2.2 HOURMETER

The Hourmeter tracks hours of operation for scheduled

maintenance:

There will be a "CHG OIL" message every 100 hours. The message

will flash one hour before and one hour after each 100 hour

interval, providing a two hour window to perform service.

This message will actually begin flashing at 99 hours and disable

itself at 101 hours, again providing a two hour window to perform

the service.

Every 200 hours the "SVC" icon on the lower left hand corner of

the display will flash. The message will flash one hour before and

one hour after each 200 hour interval providing a two hour window

to perform service.

When the hour meter is in the Flash Alert mode, the maintenance

message will always alternate with elapsed time in hours and

tenths. The hours will flash four times, then alternate with the

maintenance message four times until the meter resets itself.

• 100 hours - CHG OIL — Oil Change Interval (Every 100 hrs)

• 200 hours - SVC — Air Filter Interval (Every 200 hrs)

Operation

2.3 CORD SETS AND CONNECTION PLUGS

2.3.1 120 VAC, 20 AMP, DUPLEX RECEPTACLE

This is a 120 Volt outlet protected against overload by a 20 Amp

push-to-reset circuit breaker (Figure 6). Use each socket to power

120 Volt AC, single phase, 60 Hz electrical loads requiring up to a

combined 2400 watts (2.4 kW) or 20 Amps of current. Use only

high quality, well-insulated, 3-wire grounded cord sets rated for

125 Volts at 20 Amps (or greater).

Keep extension cords as short as possible, preferably less than

15 feet long, to prevent voltage drop and possible overheating of

wires.

Figure 6 - 120 Volt AC, 20 Amp, Duplex Receptacle

2.3.2 120/240 VAC, 30 AMP RECEPTACLE

Use a NEMA L14-30 plug with this receptacle (rotate to lock/

unlock). Connect a suitable 4-wire grounded cord set to the plug

and to the desired load. The cord set should be rated for 250 Volts

AC at 30 Amps (or greater) (Figure 7).

Figure 7 - 120/240 VAC, 30 Amp Receptacle

Use this receptacle to operate 120 Volt AC, 60 Hz, single phase

loads requiring up to 3600 watts (3.6 kW) of power at 30 Amps or

240 Volt AC, 60 Hz, single phase loads requiring up to 7200 watts

(7.2 kW) of power at 30 Amps. The outlet is protected by 21/23/27

Amp (2-pole magnetic) circuit breakers for 5kW/5.5kW/6.5kW.

2.4 HOW TO USE THE GENERATOR

If there are any problems operating the generator, please call the

generator helpline at 1-888-436-3722.

2.4.1 GROUNDING THE GENERATOR

The National Electrical Code requires that the frame and

external electrically conductive parts of this generator be

properly connected to an approved earth ground (Figure 8).

Local electrical codes may also require proper grounding of the

unit. For that purpose, connecting a No. 10 AWG (American Wire

Gauge) stranded copper wire to the grounding lug and to an

earth-driven copper or brass grounding rod (electrode) provides

adequate protection against electrical shock. However, local codes

may vary widely. Consult with a local electrician for grounding

requirements in the area.

Figure 8 - Grounding the Generator

Proper grounding of the generator will help prevent electrical

shock in the event of a ground fault condition in the generator

or in connected electrical devices. Proper grounding also helps

dissipate static electricity, which often builds up in ungrounded

devices.

2.4.2 CONNECTING ELECTRICAL LOADS

DO NOT connect 240 Volt loads to 120 Volt receptacles. DO NOT

connect 3-phase loads to the generator. DO NOT connect 50 Hz

loads to the generator.

• Let engine stabilize and warm up for a few minutes after

starting.

• Plug in and turn on the desired 120 or 240 Volt AC, single

phase, 60 Hz electrical loads.

• Add up the rated watts (or amps) of all loads to be connected

at one time. This total should not be greater than (a) the rated

wattage/amperage capacity of the generator or (b) circuit

breaker rating of the receptacle supplying the power. See "Don't

Overload the Generator".

Operation

2.5 DON’T OVERLOAD THE GENERATOR

Overloading a generator in excess of its rated wattage capacity

can result in damage to the generator and to connected electrical

devices. Observe the following to prevent overloading the unit:

• Add up the total wattage of all electrical devices to be connected

at one time. This total should NOT be greater than the

generator's wattage capacity.

• The rated wattage of lights can be taken from light bulbs. The

rated wattage of tools, appliances and motors can usually be

found on a data label or decal affixed to the device.

• If the appliance, tool or motor does not give wattage, multiply

volts times ampere rating to determine watts (volts x amps =

watts).

• Some electric motors, such as induction types, require about

three times more watts of power for starting than for running.

This surge of power lasts only a few seconds when starting

such motors. Make sure to allow for high starting wattage when

selecting electrical devices to connect to the generator:

1. Figure the watts needed to start the largest motor.

2. Add to that figure the running watts of all other connected

loads.

The Wattage Reference Guide is provided to assist in determining

how many items the generator can operate at one time.

NOTE:

All figures are approximate. See data label on appliance for

wattage requirements.

2.6 WATTAGE REFERENCE GUIDE

Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Running Watts

*Air Conditioner (12,000 Btu). . . . . . . . . . . . . . . . . . . . . . . . . . 1700

*Air Conditioner (24,000 Btu). . . . . . . . . . . . . . . . . . . . . . . . . . 3800

*Air Conditioner (40,000 Btu). . . . . . . . . . . . . . . . . . . . . . . . . . 6000

Battery Charger (20 Amp). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

Belt Sander (3") . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000

Chain Saw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Circular Saw (6-1/2") . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1000

*Clothes Dryer (Electric) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5750

*Clothes Dryer (Gas) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

*Clothes Washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1150

Coffee Maker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1750

*Compressor (1 HP). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000

*Compressor (3/4 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1800

*Compressor (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1400

Curling Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

*Dehumidifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 650

Disc Sander (9"). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Edge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

Electric Blanket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

Electric Nail Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Electric Range (per element). . . . . . . . . . . . . . . . . . . . . . . . . . . 1500

Electric Skillet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1250

*Freezer . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..700

*Furnace Fan (3/5 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 875

*Garage Door Opener . . . . . . . . . . . . . . . . . . . . . . . . . . . .500 to 750

Hair Dryer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Hand Drill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250 to 1100

Hedge Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 450

Impact Wrench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

Iron. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

*Jet Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800

Lawn Mower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1200

Light Bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Microwave Oven. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700 to 1000

*Milk Cooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100

Oil Burner on Furnace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

Oil Fired Space Heater (140,000 Btu) . . . . . . . . . . . . . . . . . . . . . 400

Oil Fired Space Heater (85,000 Btu) . . . . . . . . . . . . . . . . . . . . . . 225

Oil Fired Space Heater (30,000 Btu) . . . . . . . . . . . . . . . . . . . . . . 150

*Paint Sprayer, Airless (1/3 HP) . . . . . . . . . . . . . . . . . . . . . . . . . 600

Paint Sprayer, Airless (handheld). . . . . . . . . . . . . . . . . . . . . . . . . 150

Radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 to 200

*Refrigerator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700

Slow Cooker. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

*Submersible Pump (1-1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . 2800

*Submersible Pump (1 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . . 2000

*Submersible Pump (1/2 HP) . . . . . . . . . . . . . . . . . . . . . . . . . . 1500

*Sump Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800 to 1050

*Table Saw (10") . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1750 to 2000

Television . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200 to 500

Toaster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000 to 1650

Weed Trimmer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500

* Allow 3 times the listed watts for starting these devices.

2.7 BEFORE STARTING THE GENERATOR

Prior to operating the generator, engine oil and gasoline will need

to be added, as follows:

2.7.1 ADDING ENGINE OIL

All oil should meet minimum American Petroleum Institute (API)

Service Class SJ, SL or better. Use no special additives. Select

the oil's viscosity grade according to the expected operating

temperature (also see chart).

• Above 40° F, use SAE 30

• Below 40° F and down to 10° F, use 10W-30

• Below 10° F, use synthetic 5W-30

10W-30

10 W -30

SAE 30

SA E 30

Synthetic 5W-30

Sy nth e t ic 5 W-3 0

Operation



Any attempt to crank or start the engine

before it has been properly serviced with the

recommended oil may result in an engine

failure.

• Place generator on a level surface.

• Clean area around oil fill and remove oil fill cap and dipstick.

• Wipe dipstick clean.

• Slowly fill engine with oil through the oil fill opening until it

reaches the full mark. Stop filling occasionally to check oil level.

Be careful not to over fill.

• Install oil fill cap and finger tighten securely.

• Check engine oil level before starting each time thereafter.

2.7.2 ADDING GASOLINE



Never fill fuel tank indoors. Avoid spilling

gasoline on hot engine. Never fill fuel tank

when engine is running or hot. Allow unit/

engine to cool entirely before adding fuel. DO

NOT light a cigarette or smoke when filling

the fuel tank. Gasoline is highly flammable

and its vapors are explosive.



Do not overfill the fuel tank. Always leave

room for fuel expansion. If the fuel tank is

over-filled, fuel can over flow onto hot engine

and cause an explosion or fire.

• Use regular UNLEADED gasoline with the generator engine. Do

not use any gasoline with more than 10% ethanol added. Do not

use E85 gasoline. Do not mix oil with gasoline.

• Clean area around fuel fill cap, remove cap.

• Slowly add unleaded regular gasoline to fuel tank. Fill to bottom

of screen filter. Be careful not to overfill (Figure 9).

• Install fuel cap and wipe up any spilled gasoline.

Figure 9 - Fuel Tank

DO NOT Fill Above Lip

Fuel

Fuel Tank

IMPORTANT: It is important to prevent gum deposits from forming

in fuel system parts such as the carburetor, fuel hose or tank

during storage. Alcohol-blended fuels (called gasohol, ethanol

or methanol) can attract moisture, which leads to separation and

formation of acids during storage. Acidic gas can damage the fuel

system of an engine while in storage. To avoid engine problems,

the fuel system should be emptied before storage of 30 days or

longer. See the "Storage" section. Never use engine or carburetor

cleaner products in the fuel tank as permanent damage may occur.

2.8 TO START THE ENGINE



Never start or stop engine with electrical

devices plugged into the receptacles AND

devices turned on.

• Unplug all electrical loads from the unit's receptacles before

starting the engine.

• Make sure the unit is in a level position.

• OPEN the Fuel Shut-off Valve (Figures 10 and 11).

Figure 10 - Fuel Shut-off Valve

Figure 11 - Fuel Shut-off

Operation

• Turn engine RUN/STOP switch to ON position (Figure 12).

• Pull engine CHOKE knob outward to FULL CHOKE position

(Figure 12).

• To start engine, firmly grasp the recoil handle and pull slowly

until increased resistance is felt. Pull rapidly up and away.

• When engine starts, move choke knob to 1/2-CHOKE position

until engine runs smoothly and then fully into RUN position. If

engine falters, move choke back out to 1/2-CHOKE position

until engine runs smoothly and then to RUN position.

NOTE:

If engine fires, but does not continue to run, move choke lever

to FULL CHOKE and repeat starting instructions.

Figure 12 - Choke Position

IMPORTANT: Do not overload the generator. Also, do not overload

individual panel receptacles. These outlets are protected against

overload with push-to-reset-type circuit breakers. If amperage

rating of any circuit breaker is exceeded, that breaker opens and

electrical output to that receptacle is lost. Read “Don’t Overload the

Generator” carefully.

2.9 STOPPING THE ENGINE

• Shut off all loads, then unplug the electrical loads from

generator panel receptacles. Never start or stop the engine with

electrical devices plugged in and turned on.

• Let engine run at no-load for several minutes to stabilize the

internal temperatures of engine and generator.

• Move Run/Stop switch to OFF position.

• Close fuel valve.

2.10 LOW OIL LEVEL SHUTDOWN SYSTEM

The engine is equipped with a low oil level sensor that shuts down

the engine automatically when the oil level drops below a specified

level. If the engine shuts down by itself and the fuel tank has

enough gasoline, check engine oil level.

2.10.1 SENSING LOW OIL LEVEL

If the system senses a low oil level during operation, the engine

shuts down. The engine will not run until the oil has been refilled

to the proper level.

3.1 MAINTENANCE SCHEDULE

Follow the calendar intervals. More frequent service is required

when operating in adverse conditions noted below.

Check Oil Level At Each Use

Change Oil *Every 100 hours or Every Season

Check Valve Clearance ***Every Season

Service Air Filter ** Every 200 hours or Every Season

Replace Spark Plug Every Season

* Change oil and oil filter every month when operating under heavy load or in high

temperatures.

** Clean more often under dirty or dusty operating conditions. Replace air filter

parts if they cannot be adequately cleaned.

*** Check valve clearance and adjust if necessary after first 50 hours of

operation and every 100 hours thereafter.

3.2 PRODUCT SPECIFICATIONS

3.2.1 GENERATOR SPECIFICATIONS

Rated. Power ..............................................................5.0/5.5/6.5 kW**

Surge Power ...............................................................6.25/6.88/8.0 kW

Rated AC Voltage ......................................................................120/240

Rated AC Load

Current @ 240V (5.0/5.5/6.5 kW) ..................20.8/22.9/27.1 Amps**

Current @ 120V (5.0/5.5/6.5 kW) ..................41.7/45.8/54.2 Amps**

Rated Frequency .................................................... 60 Hz @ 3600 RPM

Phase ................................................................................Single Phase

** Maximum wattage and current are subject to, and limited by, such factors

as fuel Btu content, ambient temperature, altitude, engine condition, etc..

Maximum power decreases about 3.5% for each 1,000 feet above sea level;

and will also decrease about 1% for each 6° C (10° F) above 16° C (60° F)

ambient temperature.

3.2.2 ENGINE SPECIFICATIONS

Displacement .............................................................................. 389 cc

Spark Plug Type ................................NHSP F7RTC or Champion RN9YC

Spark Plug Gap (5.0/6.5 kW) ........0.028-0.031 inch or (0.70-0.80 mm)

Gasoline Capacity ......................................................... 6.6 U.S. gallons

Oil Type.................. See Chart in "Before Starting the Generator" Section

Oil Capacity .................................................................1.1 L (1.16 Qts.)

Class II Emission Certified*

* The engine manufacturer must warrant the emission control system

for a period of two years. This warranty coverage is in addition to

the warranty provided by Generac, and may cover the engine even if

Generac’s warranty does not.

Maintenance

3.3 GENERAL RECOMMENDATIONS

The warranty of the generator does not cover items that have been

subjected to operator abuse or negligence. To receive full value

from the warranty, the operator must maintain the generator as

instructed in this manual.

Some adjustments will need to be made periodically to properly

maintain the generator.

All adjustments in the Maintenance section of this manual should

be made at least once each season. Follow the requirements in the

"Maintenance Schedule".

NOTE:

Once a year replace the spark plug and replace the air filter.

A new spark plug and clean air filter assure proper fuel-air

mixture and help the engine run better and last longer.

3.3.1 GENERATOR MAINTENANCE

Generator maintenance consists of keeping the unit clean and dry.

Operate and store the unit in a clean dry environment where it will

not be exposed to excessive dust, dirt, moisture or any corrosive

vapors. Cooling air slots in the generator must not become

clogged with snow, leaves, or any other foreign material.

Check the cleanliness of the generator frequently and clean when

dust, dirt, oil, moisture or other foreign substances are visible on

its exterior surface.



Never insert any object or tool through the

air cooling slots, even if the engine is not

running.

NOTE:

DO NOT use a garden hose to clean generator. Water can enter

the engine fuel system and cause problems. In addition, if water

enters the generator through cooling air slots, some water will

be retained in voids and crevices of the rotor and stator winding

insulation. Water and dirt buildup on the generator internal

windings will eventually decrease the insulation resistance of

these windings.

3.3.2 TO CLEAN THE GENERATOR

• Use a damp cloth to wipe exterior surfaces clean.

• A soft, bristle brush may be used to loosen caked on dirt, oil,

etc.

• A vacuum cleaner may be used to pick up loose dirt and debris.

• Low pressure air (not to exceed 25 psi) may be used to

blow away dirt. Inspect cooling air slots and openings

on the generator. These openings must be kept clean and

unobstructed.

3.3.3 ENGINE MAINTENANCE



When working on the generator, always

disconnect negative cable from battery. Also

disconnect spark plug wires from spark plug

and keep wire away from spark plug.

3.3.4 CHECKING OIL LEVEL

See the “Before Starting the Generator” section for information on

checking the oil level. The oil level should be checked before each

use, or at least every eight hours of operation. Keep the oil level

maintained.

3.3.5 CHANGING THE OIL

Change the oil every 100 hours. If running this unit under dirty or

dusty conditions, or in extremely hot weather, change the oil more

often.



Hot oil may cause burns. Allow engine to

cool before draining oil. Avoid prolonged

or repeated skin exposure with used oil.

Thoroughly wash exposed areas with soap.

NOTE:

Whenever possible, run engine for approximately five (5)

minutes to get the engine oil hot. This will aid in draining the oil.

Use the following instructions to change the oil while the engine

is still warm:

• Clean area around oil drain plug.

• Remove oil drain plug from engine and oil fill plug to drain oil

completely into a suitable container.

• When oil has completely drained, install oil drain plug and

tighten securely.

• Fill oil sump with recommended oil. (See “Before Starting the

Generator” for oil recommendations).

• Wipe up any spilled oil.

• Dispose of used oil at a proper collection center.

3.3.6 REPLACING THE SPARK PLUG

Use Champion RN9YC spark plug or equivalent. Replace the plug

once each year. This will help the engine start easier and run

better.

1. Stop the engine and pull the spark plug wire off of the spark

plug.

2. Clean the area around the spark plug and remove it from the

cylinder head.

3. Set the spark plug's gap to 0.70-0.80 mm (0.028-0.031 in.).

Install the correctly gapped spark plug into the cylinder head

(Figure 13).

Figure 13 - Spark Plug Gap

Maintenance

3.4 SERVICE AIR FILTER

The engine will not run properly and may be damaged if using a

dirty air filter. Clean the air filter every 200 hours or once a year

(Figure 14). Clean or replace more often if operating under dusty

conditions.

• Remove air filter cover.

• Wash in soapy water. Squeeze filter dry in clean cloth (DO NOT

TWIST).

• Clean air filter cover before re-installing it.

NOTE:

To order a new air filter, please contact the nearest authorized

service center at 1-888-436-3722.

Figure 14 - Air Filter

3.5 VALVE CLEARANCE

• Intake — 0.15 ± 0.02mm (cold), (0.006" ± 0.0008" inches)

• Exhaust — 0.0020 ± 0.02mm (cold) (0.008" ± 0.0008"

inches)

After the first 50 hours of operation, check the valve clearance

in the engine and adjust if necessary.

Important: If feeling uncomfortable about doing this procedure or

the proper tools are not available, please take the generator to the

nearest service center to have the valve clearance adjusted. This is

a very important step to insure longest life for the engine.

3.6 GENERAL

The generator should be started at least once every seven days

and be allowed to run at least 30 minutes. If this cannot be done

and the unit must be stored for more than 30 days, use the

following information as a guide to prepare it for storage.



NEVER store engine with fuel in tank indoors

or in enclosed, poorly ventilated areas where

fumes may reach an open flame, spark or

pilot light as on a furnace, water heater,

clothes dryer or other gas appliance.

3.7 LONG TERM STORAGE

It is important to prevent gum deposits from forming in essential

fuel system parts such as the carburetor, fuel hose or tank during

storage. Also, experience indicates that alcohol-blended fuels

(called gasohol, ethanol or methanol) can attract moisture, which

leads to separation and formation of acids during storage. Acidic

gas can damage the fuel system of an engine while in storage.

To avoid engine problems, the fuel system should be emptied

before storage of 30 days or longer, as follows:

• Remove all gasoline from the fuel tank.





Drain fuel into approved container outdoors,

away from open flame. Be sure engine is

cool. Do not smoke.

• Start and run engine until engine stops from lack of fuel.

• While engine is still warm, drain oil from crankcase. Refill with

recommended grade.

• Remove spark plugs and pour about 1/2 ounce (15 ml) of

engine oil into the cylinders. Cover spark plug hole with rag.

Pull the recoil starter a couple times to lubricate the piston rings

and cylinder bore..



Avoid spray from spark plug holes when

cranking engine.

• Install and tighten spark plugs. Do not connect spark plug wires.

• Clean the generator outer surfaces. Check that cooling air slots

and openings on generator are open and unobstructed.

• Store the unit in a clean, dry place.

3.8 OTHER STORAGE TIPS

• Do not store gasoline from one season to another.

• Replace the gasoline can if it starts to rust. Rust and/or dirt in

the gasoline will cause problems with the carburetor and fuel

system.

• If possible, store the unit indoors and cover it to give protection

from dust and dirt. BE SURE TO EMPTY THE FUEL TANK.

• If it is not practical to empty the fuel tank and the unit is to

be stored for some time, use a commercially available fuel

stabilizer added to the gasoline to increase the life of the

gasoline.

• Cover the unit with a suitable protective cover that does not

retain moisture.



NEVER cover the generator while engine and

exhaust area are warm.

Maintenance

4.1 TROUBLESHOOTING GUIDE

PROBLEM CAUSE CORRECTION

Engine is running, but no AC output

is available.

1. Circuit breaker is open.

2. Poor connection or defective cord set.

3. Connected device is bad.

4. Fault in generator.

1. Reset circuit breaker.

2. Check and repair.

3. Connect another device that is in good condition.

4. Contact Authorized Service Facility.

Engine runs good but bogs down

when loads are connected.

1. Short circuit in a connected load.

2. Generator is overloaded.

3. Engine speed is too slow.

4. Shorted generator circuit.

1. Disconnect shorted electrical load.

2. See “Don’t Overload the Generator” .

3. Contact Authorized Service Facility.

4. Contact Authorized Service Facility.

Engine will not start; or starts and

runs rough.

1. Fuel shut-off is OFF.

2. Dirty air filter.

3. Out of gasoline.

4. Stale gasoline.

5. Spark plug wire not connected to spark plug.

6. Bad spark plug.

7. Water in gasoline.

8. Overchoking.

9. Low oil level.

10. Excessive rich fuel mixture.

11. Intake valve stuck open or closed.

12. Engine has lost compression.

1. Turn fuel shut-off ON.

2. Clean or replace air filter.

3. Fill fuel tank.

4. Drain fuel tank and fill with fresh fuel.

5. Connect wire to spark plug.

6. Replace spark plug.

7. Drain fuel tank; fill with fresh fuel.

8. Put choke knob to No Choke position.

9. Fill crankcase to proper level.

10. Contact Authorized Service Facility.

11. Contact Authorized Service Facility.

12. Contact Authorized Service Facility.

Engine shuts down during

operation.

1. Out of gasoline.

2. Low oil level.

3. Fault in engine.

1. Fill fuel tank.

2. Fill crankcase to proper level.

3. Contact Authorized Service Facility.

Engine lacks power. 1. Load is too high.

2. Dirty air filter.

3. Engine needs to be serviced.

1. Reduce load (see “Don’t Overload the Generator”).

2. Clean or replace air filter.

3. Contact Authorized Service Facility.

Engine “hunts” or falters. 1. Choke is opened too soon.

2. Carburetor is running too rich or too lean.

1. Move choke to halfway position until engine runs

smoothly.

2. Contact Authorized Service Facility.

Troubleshooting

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Manual Part No. 0H0965 Rev B (04/14/11) Printed in U.S.A.

Warranty

GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR

GP SERIES PORTABLE GENERATORS

For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants its GP Series generators will be free from defects in

materials and workmanship for the items and period set forth below. Generac will, at its option, repair or replace any part which, upon examination, inspection and

testing by Generac or a Generac Authorized Warranty Service Dealer, is found to be defective. Any equipment that the purchaser/owner claims to be defective must

be returned to and examined by the nearest Generac Authorized Warranty Service Dealer. All transportation costs under the warranty, including return to the factory,

are to be borne and prepaid by the purchaser/owner. This warranty applies only to Generac GP Series portable generators and is not transferable from original

purchaser. Save your proof-of-purchase receipt. If you do not provide proof of the initial purchase date, the manufacturer’s shipping date of the product will be used

to determine the warranty period.

WARRANTY SCHEDULE

Consumer applications are warranted for two (2) years. Commercial and Rental applications are warranted for one (1) year or 1000 hours maximum, whichever comes first.

CONSUMER APPLICATION

YEARS ONE and TWO - 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):

• Engine- All Components

• Alternator- All Components

COMMERCIAL/RENTAL APPLICATION

YEAR ONE – 100% (one hundred percent) coverage on Labor and Part(s) listed (proof of purchase and maintenance is required):

• Engine- All Components

• Alternator- All Components

NOTE: For the purpose of this warranty “consumer use” means personal residential household or recreational use by original purchaser. This warranty does not apply to units

used for Prime Power in place of utility where utility power service is present or where utility power service does not normally exist. Once a generator has experienced

commercial or rental use, it shall thereafter be considered a non-consumer use generator for the purpose of this warranty.

All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat Rate Manual.

THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:

• Generac built portable generators built prior to May 2008.

• Generac portable generators that utilize non-Generac replacement parts.

• Costs of normal maintenance and adjustments.

• Failures caused by any contaminated fuels, oils or lack of proper oil levels.

• Repairs or diagnostics performed by individuals other than Guardian/Generac authorized dealers not authorized in writing by Generac Power Systems.

• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper use. As with all mechanical devices, the Generac engines need periodic

part(s) service and replacement to perform as designed. This warranty will not cover repair when normal use has exhausted the life of a part(s) or engine.

• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire, freezing, lightning, earth-quake, windstorm, hail,

volcanic eruption, water or flood, tornado or hurricane.

• Damage related to rodent and/or insect infestation.

• Products that are modified or altered in a manner not authorized by Generac in writing.

• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or replacement of the defective part(s).

• Failure due to misapplication.

• Telephone, cellular phone, facsimile, internet access or other communication expenses.

• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty period.

• Expenses related to “customer instruction” or troubleshooting where no manufacturing defect is found.

• Rental equipment used while warranty repairs are being performed.

• Overnight freight or special shipping costs for replacement part(s).

• Overtime, holiday or emergency labor.

• Starting batteries, fuses, light bulbs and engine fluids.

THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES NO OTHER WARRANTIES AS TO THE

MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Any implied warranties allowed by law shall be limited in duration to the terms of the express warranty

provided herein. Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. GENERAC’S ONLY LIABILITY SHALL

BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES,

EVEN IF SUCH DAMAGES ARE A DIRECT RESULT OF GENERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential damages,

so the above limitation may not apply to you. This warranty gives you specific legal rights. You also have other rights from state to state.

GENERAC POWER SYSTEMS, INC.

P.O. BOX 8 • Waukesha, WI 53187

Ph: (888) GENERAC (436-3722) • Fax: (262) 544-4851

To locate the nearest Authorized Dealer visit our website www.generac.com

Part No. 0G9451 Revision E (05/19/10)